Decorative, interlocking, mortarless building block

ABSTRACT

Molded composite polymer construction blocks are made that are easily assembled, using tongues and grooves, with vertical passageways for pipes, wires, etc. Stud supporting cavities in one side of the block extend into the ribs or end walls. The cavities can be provided with protective inserts. Studs or wooden blocks can be inserted into the cavities. The wooden studs or wooden blocks of various lengths provide spacing for insulation and/or drywall installation. Internal ribs are provided with easy grip structure. One, two or three side walls of the block are provided with decorative surfaces.

BACKGROUND OF THE INVENTION

1. Field of the Invention

A building block can be made of a polymer and includes alinement ridges and channels for stack formation, sealant channels, for non-binding sealant, a cavity that can be reinforced, for studs or wood used as supports or spacers for insulation or supporting dry wall, and central passageways, for routing pipes, wires, etc., decorative surfaces, and easy grip ribs.

2. Description of Related Art

The present application is a modification and/or improvement over your applicant's similar prior published U.S. patent application No. 2004/0221538 filed 28 Apr. 2003. J. Lee (U.S. Pat. No. 541,815, issued 25 Jun. 1895) and H. Palmer (U.S. Pat. No. 674,874, issued 28 May 1901) and J. Miller (U.S. Pat. No. 800,385, issued 26 Sep. 1905) and R. Wilkinson (U.S. Pat. No. 4,573,301, issued 4 Mar. 1986) are examples of building blocks having recesses or openings for reception of building elements. C. Cahill (U.S. Pat. No. 1,950,397, issued 13 Mar. 1934) and L. Baylor (U.S. Pat. No. 2,539,177, issued 23 Jan. 1951) are examples of building blocks provided with reinforcement. R. Dula (U.S. Pat. No. 1,411,005, issued 28 Mar. 1922) and J. Linn (U.S. Pat. No. 1,780,086, issued 28 Oct. 1930) and D. Loftus (U.S. Pat. No. 1,925,103, issued 5 Sep. 1933) and Ozawa et al (U.S. Pat. No. 2001/0023559 published 27 Sep. 2001) are examples of building blocks provided with facings. J. Linn and D. Jensen (U.S. Pat. No. 5,457,926 issued 17 Oct. 1995) and Barton Jr. et al (U.S. Pat. No. 5,826,394, issued 27 Oct. 1998) are examples of building blocks having tapered ribs. Jensen et al (U.S. Pat. No. 4,193,241, issued 18 Mar. 1980) teaches a masonry block filled with insulation having a cavity to expose the “central divider” so that the block can be gripped and picked up.

SUMMARY OF THE INVENTION

A waterproof building block is formed by molding a composite polymer concrete so as to have horizontal ridges or tongues and channels or grooves on the upper and lower surfaces. Internal vertical openings provide for passage of pipes, wires, HVAC tubes, etc. A central cavity is provided in one side of the block and extends into the block central rib or end walls. A vertical central rib can be provided with a protective metal or other material insert for reception of a removable stud or a wooden block that can be used to form a spacing for support insulation and/or dry wall attachment. A composite polymer concrete can be composed of a fiber reinforced polymer composite material using a resin binder, aggregate and possible fillers formed with easy grip ribs and decorative surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building block of the invention showing the top with a wood stud inserted.

FIG. 2 is a perspective view of a building block of the invention showing the bottom.

FIG. 3 is a perspective exploded view of the building block of FIG. 1 with a section broken away and optional insert.

FIG. 4 is a perspective view of a first modification of the building block shown in FIG. 1.

FIG. 5 is a perspective view of a second modification of the building block shown in FIG. 1.

FIG. 6 is a prospective view of a third modification of the building block shown in FIG. 1

FIG. 7 is a perspective view of a fourth modification of the building block shown in FIG. 1.

FIG. 8 is a top view of the building block of FIGS. 1-3.

FIG. 9 is a cross-sectional view of a central rib with a cavity as shown by the section line 9-9 of FIG. 9.

FIG. 10 is a broken out section of one embodiment of a block front face

FIG. 11 is a broken out section of another embodiment of a block front face.

FIG. 12 is a perspective view of a wall section constructed with the building blocks of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

An interlocking building block 1, shown in FIGS. 1-3, is provided that can be manufactured from standard construction materials such as cement, sand or other fine aggregate, and coarse aggregate of less than ¾″. The block 1 is composed of a finished front wall 11, finished end walls 12, and an unfinished back wall 13, and a central rib 14. The central rib 14 contains a central cavity 2, into which a wooden 20 or other stud 24 can be inserted for fabricating a wooden support system.

The blocks can be colored and formed with decorative coverings on their front 11 and end walls 12 that resemble brick, stucco, siding, etc. The blocks are strong enough to be competitive with conventional concrete blocks. The blocks contain horizontal ridges 16, on their upper surface 18, which are designed to mate with formed channels 17 on the lower surfaces of adjoining blocks. The channels and ridges comprise a tongue-and-groove system, which serves two purposes: (1) to align one block's top surface with another block's bottom surface, and (2) to receive a non-binding sealant that will waterproof the joint of the block. Because the sealant is non-binding, the blocks can be easily disassembled and then recycled. The horizontal ridge 16 extends along the front and the ends of the upper surface 18. The channels and ridges provide the means for both rapid assembly and disassembly. They also allow easy alignment of blocks over each other. The outer walls of the block 11, 12, 13 and the interior rib shown as a central rib 14 define vertical apertures or openings 19. When the blocks are in alignment, communication is provided between the openings in the blocks that are then vertically aligned with each other. This vertical alignment of the openings 19 provides a passage for various utilities, such as electrical conduit, HVAC, or piping. A vertically elongated central recess, or central cavity 2, is made through the unfinished back side 13 and into the wider central rib 14. Obviously, the cavity is narrower than the central rib 14, and extends into the central rib without communicating with the vertical openings, or open passages 19. The inner surfaces of the cavity 2 are spaced appropriately from both the upper and lower surfaces in order to provide support and strength for wooden or other studs 20, 24 that can be inserted into the cavity.

A metallic insert 21 can be inserted into the inner surfaces of the cavity 2 as shown in FIG. 3. This metal insert is attached or bonded to the block material lining the cavity by a binder or interlocking spikes 22. The metal insert 21 is designed to distribute forces imposed by studs 20 to the building block sides and central rib material so that wear and tear on that material, due to localized forces, is reduced. The interlocking spikes 22 are formed by punching them out from the metallic insert 21. Also, there are removable stud mounting holes 23 formed in the insert. The metallic insert 21, equipped with the spikes 22 and mounting holes 23, receives wooden or other studs 20. The wooden stud has an end surface into or onto which fasteners can be attached for the purpose of hanging drywall. A non-wooden stud 24 is a removable plastic or metal preformed stud insert. It is in the shape of a “U”, and possesses a base 26 with legs 25 extending out from the base 26. Furthermore, the legs of the removable non-wooden stud are provided with protrusions 28. The removable studs 24 are held in the metallic insert 21 by means of the protrusions 28 being inserted into the stud mounting holes 23. A slightly different means is used to retain the wooden studs 20 in the metallic insert 21. The wooden stud is glued to the insert with some sort of binder or it is impaled by the interlocking spikes 22. The length of the wooden studs can be chosen so as to give the builder the choice of any desired spacing between the block and drywall, or any other finishing material attached to the outer ends of the wooden studs 20 or the outer ends of the removable stud inserts 24 and the blocks rear surfaces. The wooden studs 20 provide a space between the back side 13 of the studs and the unfinished block back side. This space can be used to position insulation between the blocks and a drywall attached to the stud ends.

The first modified block 40 shown in FIG. 4 is similar to that in FIG. 1, except that the cavity 42 is in the wider end wall 46 as opposed to being located in an interior or central rib. The same front wall 11, end walls 12, horizontal ridges 16 and grooves 17 and open passages 19 are retained. The unfinished back wall 43 accommodates the cavity 42 with a thinner central rib 44 and easy grip 45.

The further modified block 50 shown in FIG. 5 is similar to that shown in FIG. 4, except that there are two cavities 51, 52 placed in wide end walls 56, 57 respectively . The cavities 51, 52 are formed in the unfinished back wall 53. The same front wall 11, end walls 12, horizontal ridges 16 and grooves 17, and open passages 19 are retained. The unfinished back wall 53 accommodates the two end cavities 51, 52 with a thin central rib 54 and easy grip 55. The studs are housed within the cavities 51, 52.

In FIGS. 4 and 5, the intermediate ribs 44 and 54, respectively, are relatively thin as there is no need to accommodate an insertion of any type. In view of this, the easy grips 45, 55 on the central rib tops are wider than that of the central rib upper areas but are much narrower than that shown in FIG. 1, yet they still serve as easy grips for control of the blocks.

The block 60 shown in FIG. 6 is similar to that in FIG. 5, except that it is provided with two wide internal ribs 64, 65, and three vertical open passages 19. The wide central ribs each house cavities 61, 62 formed in the unfinished back wall 63. The block 60 has the same front wall 11, end walls 12, and horizontal ridges and grooves 16,17. The wide internal ribs surround the cavities to secure the studs in place. The tops of the internal ribs are provided with easy grips 66, 67.

The block 70 shown in FIG. 7 has the same front wall 11, end walls 12, back wall 73 and horizontal ridges and grooves. The central rib section of the block 70 has a wide rib upper surface 74 with easy grip 75. The rib can expand from the front to the back or can be provided with a wide section 71 having a horizontal elongated width for receiving a stud in a cavity 72 in the back wall 73. The cavity 73 in the back wall can be made at any desired angle with the back wall into the wide section 71.

FIG. 8 is a top view of the block of FIGS. 1 and 2 and FIG. 9 is a cross-sectional view of an intermediate rib along the section lines 9-9 of FIG. 8. The central rib 14 grip 5 is formed with a wider central rib top 6 than central rib upper 3 so that a worker can easily grab and move the block. The central rib has a cavity 2 between the central rib upper 3 and the central rib base 4 that accommodates a wood stud 20 or other insert. A pin hole 27 extends between the cavity 2 and a vertical opening 19 so that a securing pin or screw can be inserted from the vertical opening 19 into the cavity 2 to secure a wooden stud, for example, into the cavity.

FIGS. 10 and 11 show sections of the front faces 11 of blocks. The face 11 in FIG. 9 is formed by molding into the block thin brick sections 91 that give the appearance of a brick wall. The face 11 of FIG. 10 is formed by molding into the block a coating of brick powder 92 in any preferred decorative form.

FIG. 12 displays building blocks assembled together to form a three-tiered wall. The bottom and top tiers show wooden studs 20 inserted into the central cavities 2 on the unfinished face 13 of the blocks 1. In conjunction with the tongue-and-groove system 16, 17, there is also provided, for further securing of the wall in place, tie-down bolts 93 that passes through plates 94 and open passages 19 in the blocks.

It is believed that the construction, operation and advantages of this invention will be apparent to those skilled in the art. It is to be understood that the present disclosure is illustrative only and that changes, variations, substitutions, modifications and equivalents will be readily apparent to one skilled in the art and that such may be made without departing from the spirit of the invention as defined by the following claims. 

1. A building block comprising: a molded material forming a front wall, a back wall, end walls, a interior rib, an upper surface and a lower surface; said interior rib divides said block interior into open passages that can be alined to accommodate equipment; said interior rib having an upper surface and a lower surface and a central width between said upper surface and said lower surface; said interior rib upper surface being wider than said upper central rib adjacent said interior rib upper surface, providing an easy grip for control of said building block
 2. A building block as in claim 1 including: a cavity in said back wall extending into said molded material of said block below said upper surface and above said lower surface and between said end walls.
 3. A building block as in claim 2 including: a metal insert secured within said cavity for securing a spacing member therein; said metal insert having interlocking spikes for securing a wooden spacing member and mounting holes for securing a non-wooden spacing member; said cavity is narrower than said interior rib and extends within said interior rib without communicating with said open passages.
 4. A building block as in claim 2 wherein: said cavity has a rectangular configuration with the longest dimension being horizontally oriented.
 5. A building block as in claim 2 wherein: said cavity has a rectangular configuration with the longest dimension being horizontally oriented.
 6. A building block as in claim 2 including: said interior rib is centrally located and divides said block interior into two open passages.
 7. A building block as in claim 2 wherein: said block upper surface is provided with tongues; said block lower surface is provided with grooves such that said upper surface tongues can be placed within said lower surface grooves to aline blocks.
 8. A building block as in claim 2 wherein: said block front wall has decorative facing molded therein.
 9. A building block as in claim 8 including: said block upper surface is provided with tongues; said block lower surface is provided with grooves such that said upper surface tongues can be placed within said lower surface grooves to aline blocks.
 10. A building block as in claim 8 wherein: said decorative facing includes thin bricks molded into said block face.
 11. A building block as in claim 8 including: said decorative facing includes brick powder molded into said block face.
 12. A building block as in claim 2 including: said cavity is narrower than said end walls and extends within an end wall.
 13. A building block as in claim 2 including: two cavities in said block back wall; said cavities are narrower than said end walls and extend within said end walls.
 14. A building block as in claim 12 including: a metal insert secured within said cavity for securing a spacing member therein.
 15. A building block as in claim 14 wherein: said block upper surface is provided with tongues; said block lower surface is provided with grooves such that said upper surface tongues can be placed within said lower surface grooves to aline blocks; said block front wall has decorative facing molded therein.
 16. A building block as in claim 2 wherein: a reinforcing insert within said cavity for force distributing.
 17. A building block as in claim 16 wherein: said reinforcing insert is a u-shape metallic insert.
 18. A building block as in claim 17 wherein: said u-shaped metallic insert is provided with spikes and stud mounting holes and a pin hole for securing said u-shape metallic insert into said cavity and a stud into said u-shape metallic insert. 